Catalytic ammonia synthesis



\ f insects CATALY'EKC AMMQNIA SYNTHESHS oi Belaware No Drawing.

Application March 8, 1928 Serial No. 260,262

X Claims.

This invention relates to tne synthesis of arm monia by the catalytic combii .1 or" hydrogen and nitrogen at high pressures and temperatures.

According to the present invention nydrogen 'proioerties of exchanging their bases for other solutions. base exclian prod cts used in catalytic composn' 1S tn invention or as initial material for derivatives to so used may high base power or in many cases may possess lower exchanging power, since the catalytic Value of the n. al compositions is not primarily base exchanging in general the base exchange be (lit/led into three main cate- :i?wo-component niultncomponent e., ex hange bodies containing shined con in tn l: nucleus and so exchange bodies in which all replaced by other suitable acidic metal oxides. Two-component zeolites t e reaction products of two types of initial that is to say, nietallates silicates, the term metaliate in a vinaias will be defined further the description), salts and sili- "equentiy more tit n on member of a ter into reaction, that is to say, a 5.311 one metaliate more tlian one metal sa The multi-component zeolites the reaction products of at dependent on the amount of power present.

bodies least three types of components, that is to say,

at least one s li ate. at least one tallate, and

at least one i salt.

bodies, both zeolites and ge bodies, may be assorably in the form of a as will be depnysically no. scribed below. exchange bodies y n the contact on, or their K base flange bodies are l Zed and undiluted products odies, zeolites and non s, also be transicn oossess many of the physical characteristics of the parent base exchange bodies. Such derivatives may be salt-like bodies, that is to say, the reaction products of base exchange bodies with compounds containing anions capable of reacting ltli the base exchange bodies to form products which possess many of the properties of salts. A further class of derivatives are the acid leached. exchange bodies. base exchange. body is subjected to leaching-by acids, particularly dilute mineral acids, the exchangeable, bases are first gradually removed. The resultirnaproducts contain both the more basic and the acidic components of the nonexcliangeable nucleus of the base exchange body, with or without a portion of the exchangeable bases. the leaching is carried on further, more and more of relatively positive components of the noneexchaneeable nucleus are removed, and it carried to. completion the leached product contains only'the relatively acid components of the non-exchangeable nucleus. In the case of zeolites the final product from long continued leaching is a complex silicic acid which has many of the physical properties of the original base exchange body. In the description and claims the class or" base exchange bodies and their saltlike bodies and leached derivatives will be referred to by the generic term perinutogenetic products.

Catalytically active components may be asso ciated with diluted or undiluted permutogenetic bodies four rne follows: (1) They may be physically admixed with or impregnated into the permutogene ic products. (2) They may be phy i ally homogeneously incorporated into the pei'inutog'enetlc products before the latter have been completely formed in the form of catalytically active diluent bodies or in the form of diiuents w? ion have been impregnated with catalytically active substances. (3) They may be chemically combined with or in the permutogenetic products in non-exchangeable form, that is to say, they may form a part of the non-exchangeable nucleus of the base exchange body present in the final contact mass or which is transformed into the .erivati es, or they may be chemically combined with the base exchange bodies in the form of catalytically active anions which form with the base exchange body salt- When a above described forms, and it is an advantage of the present invention that catalytically active substances may be introduced in a Wide variety of forms which gives a large field of choice to the catalytic chemist.

While the different permutogenetic products may vary widely in their chemical characteristics, they all possess a similar physical structure which is characterized by more or less high porosity, frequently microporosity, and great re-- sistance to high temperatures, and in the case of products which have not been acid leached to the-point of removal of catalytically active components these .components are distributed throughout the framework of the products in atomic or molecular dispersion, as will be described in greater detail below, and this chemical homogeneity is one of the important advantages of some of the contact masses of the present invention. 7

While three of the methods of combination of the catalytically active substances may be effected with undiluted as'well-as' diluted permutogenetic products, it has been found that homogeneously diluted permutogenetic contact masses are of advantage, particularly where the diluents are of a physical nature such as to exert a desired influence on the catalytic activity of the contact masses, as when, for'example, diluents are rich in silica, which has been found to have. an activating power, or where the diluents by reason of high porosity, capillarity, or surface energy may be considered as physical catalysts or activators. Ease exchange bodies used in contact masses I of the present invention behave as ifthey were products of extremely high molecular weight for catalytically active components can be introduced either into the non-exchangeable'nw C1\'3US or in the form'of exchangeable bases in practically any desired proportions and the ordinary'law of chemical combining proportions, which in compounds of low molecular weight restricts the proportions in which components can be incorporated chemically, appears to be without force, which makes it reasonable to assume that the molecular weight is so high as to completely mask the effect of the law.' It is of course possible that the base exchange bodies, or some of them, may be solidsolutions of a plurality of related compounds of lowermolecular weight. It has not been possible hitherto to definitely settle this question, as base exchange bodies are not readilycapable of structural chemv ical analysis. The present invention is of course not limited to any theory, but irrespective of the underlying reasons the fact that catalytically active components may be chemically introduced in any desired proportions is of enormous importance to the catalytic chemist and gives him the power to produce an almost unlimited number of finely and gradually toned catalysts or contact masses for the synthesis of ammonia and in all cases the contact masses produced are highly effective by reason of the desirable physical structure of the permutogenetic products contained therein and the wide limits of homogeneous dilution of catalytically active molecules or atoms with resulting uniformity and smoothness of action.

In addition to the important characteristics with which permutogenetic products endow the contact masses of the present invention it has been found that it is frequently desirable to stabilize the contact masses, and this may be effected by associating with the permutogenetic products or incorporating or forming therein compounds of the alkali forming metals, that is to say, the alkali metals, the alkaline earth metals, and the strongly basic earth metals. These compounds appear to slow up or smooth out the catalytic reaction, and will be referred to throughout this specification as stabilizers. The stabilizers may be non-alkaline, weakly alkaline or strongly alkaline, depending on the nature of the catalytically ctive components used. It is a great advantage of the present invention that in the normal formation of base exchange bodies alkali forming metal oxides are present as exchangeable bases, and whether used Without acid treatment or treated with acid, they form stabilizers which are combined in 01' associated with the resulting permutogenetic products in an extremely fine state of division in which the stabilizers are peculiarly active. Thus base exchange bodies containing alkali forming metal exchangeable bases may be considered as complex stabilizers.

' In addition to the use of stabilizers, it has been found that the stabilizer action and the the reaction conditions obtaining will be referred to throughout the specification as stabilizer promoters, as they appear to enhance the toning effect which can be achieved by stabilizers. The use of this expression should, however, in no sense be taken to limit the invention to a particular theory of action of these non-specific catalysts and in fact in some cases stabilizer promoters may be present where there are no stabilizers.

The tremendous range of chemical groups which may be combined in or with or incorporated in permutogenetic products permits a wide choice of stabilizer promoters as well as specific catalysts and permits their association with the contactmasses in an extremely homogeneous and catalytically eflicient form. Thus many base exchange bodies or their derivatives may be considered as complex catalysts, stabilizers and stabilizer promoters, as all of these elements may be present in the same chemical compound and sharing the advantages flowing from its desirable physical structure and chemical properties. Of course both stabilizer and stabilizer promoters may be mixed partly or wholly with permutogenetic products and a single stabilizer or single stabilizer promoter may be present partly in physical admixture and partly in chemical combination, as will be clear to the skilled base exchange chemist.

The base exchange bodies which form the important components or initial material for derivatives in contact masses of the present invention may be prepared by any of the well known methods. Thus for example, two-component zeolites may be prepared by wet methods, in which the metallate components or metal salt components, part or all of which may be catalytically active, are caused to react with soluble silicates to form zeolites of aluminosilicate or aluminum double silicate types, or the components may be fused, preferably in the presence of fluxes. It should be understood that under the term metallate is included not only the alkaline solutions of amphoteric metal: oxides or hydroxides but also alkali forming metal salts of acting with silicates to form zeolites, or with other components to form non-silicious base exchange bodies.- Throughout the specification this somewhat more eneral definition of met allatcs will be strictly adhered to. In the forma tion of two-component zeolites by wet methods,

the final reaction product must be alkaline to litmus, and for products of. high base exchanging power it should be neutral or alkaline to phenolphthalein. For the purpose of producing base exchange bodies to be used in the preparation of contact masses or" the present invention it is sometimes unnecessary to provide high base exchanging power, and for many purposes zeolites formedunder conditions resulting in a final reaction which is acid to phenolphthalein but alkaline to litmus are of advantage. It is not definitely known whether products produced under such circumstances are homogeneous, chemical compounds, although in many ways 1 they behave as such. There is, however, reason.

to believe that in some cases at least mixtures of a base exchanging and non-base exchanging polysilicates may be produced.

For the purpose of the present specification a product will be considered as a base exchange product if it has any base exchange power at all.

It is desirable for many purposes and particularly where two component zeolites of high base exchanging power are needed to add the relatively acid components, for example, metal salts in the case of aluminum double silicate type oi zeolites, to the relatively more alkaline components such as for example soluble silicates. By these means a continuous alkalinity is insured, and this method may be considered as the preferred method in most cases, but the opposite procedure is advantageous for certain contact'masses and is included in the invention.

ltiuiti-cornponent zeolites may be prepared by any of the foregoing methods using at least three types of components, that is to say, at least one nietallate, at least one metal salt and at least one soluble silicate. In the case of multicomponent zeolites, as in the case of two-co1nponent zeolites, the conditions of alkalinity should be observed, and for many purposes it is advantageous to add the relatively acid GOTH- ponents to the relatively alkaline components, in order to insure continuous alkaline reaction. The multi-component zeolites produced vary in their nature, dependent on the proportion of the difierent reactin components. Thus where the metallates and silicates predominate over the metal salts the resulting products resemble the alumino silicate type of two-component zeolites. If the metal salts and silicates predominate over the metallatcs the products resemble the aluminum double silicate type of two-component zeolites, and finally if the metaliates and metal salts predominate over the silicates the resulting product resembles more or less non-silicious base ex hange bodies. it will be clear that there is no sharp defining line between the three types of multi component zeolites, and one shades into the other if the proportions of the diiierent components vary. It is an advantage of the multicomponent zeolites over the two-component zeolites that the choice of catalytically active components is Wider, as some catalytically active elements or groups can only be incorporated in the form of metallates and others only in the form of metal salts. In a multicoinponent zeolite each catalytically active group can be incorporated in the form in which it is best available.

Non-silicious base exchange bodies are produced by the general methods described above, but instead of bringing about reactions between silicates and other metal oxide components, two or more oxymetal compounds are caused to react, in general, at least one will be a metallate and at least one a metal salt, or in some cases it is possible to bring about action between two different metallates in which one negative radical is more acidic than the other. It is possible to produce non-silicious base exchange bodies in which a plurality of ,metal oxides are present. Itis also possible to produce non-silicious base exchange bod-es. in which a single metal is present. Thus for example, some metals may be sufficiently amphoteric in character to form both meta-llates and metal salts which are capable of reacting with each other to produce base exchange bodies.

A special method of producing non-sii'cious base exchange bodies consists in the gradual neutralization of strongly alkaline salts of the oxyacids of metal elements of the fifth and sixth groups in stages of oxidation in which they are suflici'ently amphoteric. The neutralization of other strongly alkaline metallates may also bring about formation of non--silicious base exchange bodies. The. converse method, whereby nonalkaline salts of suitable metals are gradually treated with alkali until the reaction is sufficiently alkaline to permit the formation of base exchange bodies, may also be used.

Many metals are capable of entering into the base exchange body formation only in certain stages of oxidation, and it is sometimes necessary tointroduce such metals in a oi oxidation different from that desired in the final base exchange body, the change of of oxidation being preferably efiected during the formation of the base exchange body. Certain other elements maybe incorporated in the form of complex com-- pounds or" the mostv various types, such for example, ammonia complexes and the like.

In addition to the artificial. base exchange bodies briefly described above, natural. base exchange bodies, such as' nephcline, leucite, ielspar, and the like, may. be used.

The most important contact masses for many reactions contain permutogenetic products, in which. preferably the diluents are homogeneously incorporated into the base exchange bodies be fore formation of he latter, or at least before the base exchange body set after formation. Many diluents, both insert, stabilizing, activating, catalytically active, or having stabilizer pro moter efiocts, can be used. A few of the diluents will be briefly enumerated:-kieselguhrs of all J kinds, particularly natural or treated celie earth, sullicious powders of various types, powdered permutogenetic products, natural or artificial powders of rocks, stones, tufts, trass, lava, and si1ni-- larly volcanic products which are frequently highly porous, greensand, glauconite or its acid leached derivative glauccsil, pulveized slag wool, cements, sand, silica gel, pulverized earthenware, fullers earth, talc, glass powder, pumice meal, meerschaum, magnesia, asbestos, graphite, activated carbon, quartz meal, various pulverized Cit minerals rich in quartz, metal powders and metal alloy powders, or spongy metals, salts of oxymetal acids'such as tungstates, vanadates, chromates, uranates, manganates, cerates, molybdates, etc., particularly salts of the above, sili-' cates, such as copper silicate, iron silicate, nickel silicate, cobalt silicate, aluminum silicate, titanium silicate, minerals or ores, especially those rich in copper, etc. Finely divided diluents are of great advantage, especially when the average particle size is less than microns, in which case the diluents possess high surface energy, which increases the adsorptive and absorptive capacity of the contact mass, the diffusion speed and porosity.- These finely divided diluents may be considered as physical catalysts or activators. Diluted permutogenetic bodies may also be finely divided and used as part or all of the diluents of other base exchange bodies.

The following nine methods are the most effective for the introduction of diluents, but any other suitable methods can be used:

(1) The diluents may be mixed with one or more liquid components of the base exchange bodies to be formed when the latter are prepared by wet methods.

(2) Components, either catalytically active, stabilizer promoters, or others, may be precipitated or impregnated into diluent bodies which are then incorporated into the base exchange bodies by any suitable methods of incorporation.

(3) Diluents may be mixed with base exchange bodies when the latter are still in the form of gels, by kneading or stirring,'in which case the base exchange gel behaves as an adhesive. The homogeneity and uniformity of the distribution of the diluents is of course not quite so great by this method as by method (1), but for the .synthesis of ammonia extreme uniformity isnot essential.

(4) Diluents may be formed during the formation of base exchange bodies by mixing suitable compounds with the components of the base exchange bodies so that the diluent particles are precipitated during formation. Protective colloids may be added to prevent coagulation. of the diluent particles before the base exchange bodies havebecome suiliciently set.

(5) Compounds may be added which react with certain of the base exchange bodies forming components to produce diluents, for instance salts of the metal acids of the fifth and sixth groups may be added in sufi'icient excess so that they react with components of the base exchange body'to form insoluble diluents, as for example with heavy metal oxides. I

(6) Preformed base exchange bodies, diluted or undiluted, artificial or natural, can be impregnated with true orcolloidal solutions of catalytically effective components and then dried.

(7) A preformed base exchange bodly, diluted or undiluted, may be impregnated with a plurality of solutions which react therein to precipitate any desired diluents.

(8) Soluble diluent compounds may be added to the components forming a base exchange body, which after formation retains the compounds in solution and is dried without washing or is treated to precipitate the compounds.

(9) Natural base exchange bodies or artificial base exchange bodies, diluted or undiluted, or their derivatives, may be impregnated with solutions of the desired compounds, which are then precipitated by means of reactive gases.

The nucleus or non-exchangeable portion of the molecules of the base exchange bodies is ordinarily considered to consist of two types of oxides, namely, relatively basic metal oxides, usually amphoteric, and relatively acidic oxides, such as SiOz, some amphoteric metal oxides and some metal oxides which have a distinctly acid character. The nucleus behaves as a single anion and cannot be split by ordinary chemical means, but

'it is advantageous to consider the two portions of the nucleus as the basic and acidic portions, bearing in mind of course that the nucleus behaves as a single group. The metal compounds which are capable of forming the basic portion of the nucleus are those of the following metals: copper, silver, gold, bismuth, beryllium, zinc, cadmium, boron, aluminum, some rare earths, titanium, zirconium, lead, thorium, niobium, antimony, tantalum, chromium, molybdenum, tungsten, uranium, vanadium, manganese, iron, nickel, cobalt, platinum, palladium. Compoundsof these elements may be introduced singly or in mixtures, in any desired proportions, and may be in the form of simple or complex ions. It should be understood that some of the elements in certain stages of oxidation may be introduced either as metallates or metal salts. Others may be introduced in only one form, and still others may be introduced in a'stage of oxidation other than that desired in the final base exchange body or in the form of complex compounds. Among the complex iongens are ammonia, hydrocyanic acid, oxalic acid, formic acid, tartaric acid, citric acid, glycerine, and the like.

Many of the metals are specific catalysts, others are stabilizers, and still others are stabilizer promoters.

Examples of components forming the relatively acid portion of the base exchange nucleus are alkali metal silicates, which are soluble in alkali, and alkali metal salts of acids, such as those of boron, nitrogen, titanium, vanadium, tungsten, chromium, niobium, tantalum, uranium, antimony, manganese, etc.

-The exchangeable bases of the base exchange bodies may be substituted by base exchange, and the elements which can be introduced singly or in admixture by base exchange are the following:copper, silver, gold, ammonium, beryllium, calcium, manganese, caesium, potassium, sodium, zinc, strantium, cadmium, barium, lead, aluminum, scandium, titanium, zirconium, tin, antimony, thorium, vanadium, lithium, rubidium, thallium, bismuth, chromium, uranium, manganese, iron, cobalt, nickel, ruthenium, palladium, platinum and cerium.

The exchangeable bases introduced may be specific catalysts, they may be stabilizers, or they may be stabilizer promoters. They may be introduced as simple ions or as complex ions, and may enhance the catalytic activity of the final contact mass, improve its physical strength, or both.

As has been described above, base exchange bodies can be caused to react with compounds containing acidic radicals capable of forming therewith salt-like bodies. The radicals may be present in the form of simple acid radicals, polyacid radicals or complex acid radicals, and in clude radicals containing the following elements:chromium, vanadium, tungsten, uranium, molybdenum, manganese, tantalum, niobium, antimony, bismuth, boron. Among the complex radicals are ferro and ferricyanogen, certain ammonia complexes and the like. The amount of acid radicals caused to unite with the base exchange bodies to form salt-like bodies may be varied so that the resultchlorine, platinum,

ing products may possess the character of acid, neutral or basic salts. Most of these acid radicals are stabilizers or stabilizer promotors for the catalytic synthesis of ammonia.

The base exchange bodies diluted or undiluted, or some of their salt-like body derivatives, may be treated with acids, such as mineral acids, for example, 2- l0% sulfuric, hydrochloric or nitric acids, to remove part or all of the exchangeable bases, or also part or all of the basic portion of the nucleus.

In the case of zeolites, the partial leaching with acids, which leaves part or all of the basic portion or" the nucleus or even part of the exchangeable bases, does not affect the function of the zeolites as catalysts when they contain catalytically active elements in the basic portion of the nucleus, or in some cases even exchangeable bases, and such partially leached catalysts are of great importance. Where the leaching is carried out to completion the advantageous physical structure remains to a considerable extent the same but the remainder is of coursea form-of silica, or in the case or zeolites in which part of the silica is replaced by other acidic compounds, a mixture of the two, and usually will not be a specific catalyst for he reduction or hydrogenation of oxides of carbon. It serves, however, as an advantageous physical carrier of specific catalysts, and in the case of partially substituted zeolites may also contain stabilizer promoters.

Leached non-silicious base exchange bodies, either partially or completely leached, may contain catalytically active components and behave as catalysts, stabilizer promoters or both, and many important catalysts for thereduction and hydrogenation of carbonyl compounds are thus obta ned. This is particularly the case where a relatively alkali=-free contact mass is required for best results and where the alkali content of a contact mass containing a'base exchange body may be too great for optimum results.

Base exchange bodies or their derivatives, d'i

luted or undiluted, may also be coated in the form offilms on massive carrier granules may be impregnated therein. The massive carriers may be inert, activating, or themselves catalysts. For example, certain catalytic metal alloys, minerals, fall wi hin this class. ilunrlnuin or copper alloy granules perform an additional advantageous function in that their relatively high heat conductivity tends to prevent local overheating which is of considerable importance in obtaining good yields, as the reaction is an equilibrium reaction. a

'It is desirable in many cases to subject the contact masses to a preliminary treatment at elevated temperatures with air, nitrogen, hydrogen or mixtures of nitrogen and hydrogen- It is also advantageous in some cases to introduce ammonium as an exchangeable base, which is later set free during catalysis and which increases the effectiveness of many of the contact masses of the present invention.

The invention wil-lbe described in greater detail in connection with the examples which 101- low and which illustrate the typical ammonia syntheses "embodying the features of the present invention. The invention, however, is in no sense limited to the details 01 the examples which. are

representative illustrations only.

Example 1 15 parts of aluminum oxide, 11.5 parts of airture of conium oxide and 18 parts of anhydrous potassium carbonate are ground together and intimate'ly mixed with 100 parts or" iron oxide, preferably magnetic iron oxide or with a correspond ing amount of powdered iron. The mixture is then fused and the fused material broken into pieces and treated with water. The product is a non-silicious base exchange body and after drying it can be used as a contact mass for the catalytic synthesis of ammonia.

instead 01- carrying out the fusion as described, an intimate r of iron oxide, aluminum oxide, zirco un oxide and anhydrous potassium used into a tower and a hot mixture and a combustible organic substance. such naphthalene, is passed over The gases should have a tempera- -550 C. Catalyticoxidation takes place and the organic substanceis'completely burned, the heat evolved causing the components of the catalyst to sinter together or to completely melt. The sin-tered or melted material is broken into suitable pieces andhydratecl with Water.

A contact mass as described in either of the foregoing paragraphs is filled into a converter and giv n a short preliminary treatment $3-fi8il C. with gases containing ammonia.

Thereupon a mixture of hydrogen and nitrogen ammonia are produced and the ammonia is washed out of the gas stream whereupon the unreacted gases, after adjustment oi'coniposition by the addition of fresh gases, are recirculated.

Instead of pretreating the contact mass with v gases containing ammonia, a 10% ammonium chloride solution may be permitted to trickle over thecontact mass after hydration resulting in the replacement of part of the exchangeable alkali by ammonia. The contact mass thus obtained can be directly filled into'a high pressure Example 2 1,000 "parts of freshly precipitated. iron oxide are suspended in 300 parts of water to form a slurry. 15 parts of freshly precipitated aluminum oxide are dissolved in 2 N. potassiurnhydroxide to form potassium aluminate containing a 20% excess of the alkali. The iron oxide is then stirred in and finally a 5% solution containing zirconium nitrate, zinc nitrate, and cadmium nitrate in the ratio of 2: 1: l is added to the aluminate-iron oxide suspension until the final reaction mixture just remains alkaline to phenolphthalein. The product is sucked and died at temperatures below (3., whereupon it is broken into fragments. The resulting mass con-' tains a "non-silicious base exchange body impregnated with iron oxide. The uniform distribution of the base exchange body which acts as a stabilizer and stabilizer promoter enhances the catalytic activity of the iron oxide in an excellent manner. Thephysical structure of the base ex- Example 3 Fragments of iron of any desired size are exposed to wet air inorder to coat them with a film of iron oxide. They are then placed in a kettle converter anda hot mixture of air and an organic substance, such as naphthalene, is passed over at 450-500 C, Catalytic oxidation takes place and the organic substance is completely burned, the heat evolved causing the iron to sinter or melt and at the same time removing the undesired impurities from the iron. The sintered or melted material which consists of magnetic iron oxide is then ground and added to a waterglass solution containing 15-90 parts of S102 diluted with 20-25 volumes of water. The magnetic iron oxide should be added'until the suspension just remains readily stirrable. The waterglass-iron oxide suspension is warmed and a saturated water solution containing 11.6 parts of WC: in the form of potassium tungstate, 7.2 parts of M003 in the form of potassium molybdate, and 9 parts of V205 in the form of potassium v anadate is stirred in. Tov the mixture thus produced, a 10% solution containing 20 parts of.

zirconium nitrate with 5 mols of water and 34 parts of thorium nitrate with 12 parts of water is added with vigorousagitation whereupon the reaction mixture gelatinizes. The speed or" gelatinization may be increased by a cautious addition of a small amount of nitric acid but care shouldbe taken that the reactionmixture remains neutral or slightly alkaline to phenolphthalein. The gel is pressed, dried and washed with ammonia water, the resulting product being a base exchange body containing tungsten, molybdenum, vanadium, zirconium, and thorium in non-exchangeable form and being diluted with a special mixture ofiron oxide in a finely divided uniformly distributed state. The base exchange body after drying may be treated with a. 2-5% nitric acid solution in order to remove part of the exchangeable alkali, resulting in a partially leached permutogenetic body or if desired the base exchange. body after hydration with water may be submitted to base exchange by causing a diluted cerium nitrate solution to trickle over it in order to exchange part of the sodium for cerium. The product is dried, reduced with hydrogen at 300-40050. and is an excellent contact mass for the synthesis of ammonia under the reaction conditions described in the foregoing examples. Other elements than cerium can also be introduced by base exchange, such as aluminum, iron, manganeseQstrontium, cobalt, beryllium, rare earths otherthan cerium, zirconium, titanium, chromium, zinc, lead, cadmium, copper, silver, etc. The introduction whichmayxbe of one or more of the elements above enumerated is perfectly efiected by trickling dilute salt solutions of the elements. over the base. exchange body. a A further modification consists in the treatmerit of the base exchange body by spraying with nitric acid in order to form the nitrate, a socalled salt-like body of the base exchange body, or the treatment may be efiected by means of water-soluble salt solutions of the metalacids of the 5th and 6th groups of the periodic systernsuch as ammonium vanadate, ammonium molybdate, or ammonium tungstate. The ase exchange bodies may also be treated with ammonia-or cyanogen complexes in order to form complex salt-like bodies. The salt-like bodies are preferably. subjected to preliminary treatment with gases containing ammonia, hydrogen or a mixture of hydrogen and nitrogen.

Example 4 24-parts SiOz in the form of a sodium or potassium waterglass solution diluted with i or 5 volumes of water, are mixed with sufficient of a 10% solutionpf salts of chromium, tetravalent vanadium, zinc, lead, cadmium, copper, iron, aluminum, beryllium, zirconium, titanium or cobalt, singly or in admixture, for example a 10% solution of one or more or" the nitrates. The addition of the salt solution should be suflicient to cause the reaction mixture to remain alkaline to litmus and preferably neutral or alkaline to phenoiphthalein. A gel ,is obtained consisting of a two component zealite. The gel is separated from the mother liquor and dried at temperatures belowl09 C.

Instead of using salts the correspondingmetallatesmay be used such as alkali metal-beryllate, aluminate, chromite, vanadite, plumbite, cadmiate or zincate. .When using a metallate solution it is desirable to accelerate the reaction by the addition of sufficientacid toneutralize the excess alkalinity. The gel obtained is freed from the mother liquor, washed with water and then dried at temperatures up to 100 C. The base exchange bodies obtained as described above are preferably treated with salt solutions such as manganese nitrate, thorium nitrate, copper nitrate, zirconium nitrate or titanium nitrate, the

solution preferably being of 5 to 10% strength and being permitted to trickle over the base exchange body in order to substitute part of the exchangeable alkali.

A furthei modification consists in treating the base exchange bodies obtained with salts of the metal acids of the 5th and 6th group of the periodic system, for example using 1% solutions of ammonium yanadate, ammonium moylbdate or ammonium tungstate or a mixture of two or more of them. The so-called salt-like bodies are obtained and if desired the metal acids may be replaced with nitric acid in order to form the nitrate, the nitric acid of course being applied in such a manner as to prevent leaching.v I d Other eife'ctive contact masses of the class described above can be prepared by leaching the base exchange bodies with dilute acids before or after base exchange or before or after salt like body formation. It will be noted that the catalytically efiective elements may be present either in the complex nucleus inthe-form of exchangeable bases or in the form of anions in the salt like bodies.

Very desirable contact masses may also be ob-. tained by diluting 'permutogenetic bodies, preferably during formation, with diluents which may be inert, stabilizers or s'tabilizer promoters or. even themselves catalytically eirective products. Examples of such diluents are asbestos, meerschaum, pumice,- fire brick, A1203, kieselguhr, 1

activated carbons of various kinds, graphite, metals, metal alloys, magne a, and the like. Instead of incorporating diluents in the base exchange body in the perroutoge c body the lat may be coated on. er fragments in the form of f1 ziainnles of carrier -fragments are roughened ali such. ferro-inolybden n1, ferrochrcine, ierrovanadiuni, silico-ierronianganese, silica-ale "i'errorna'iganese, ierrotitani'uin, ierrotung n, i iclzel and the lilac. If necessary adhesives may be usedto cause the film. to to the carrier flagnients. the examples or alkali earth metal cy ing ierroor ferricyanides.

Before using the contac to subject them to a rural hydrogen or hydrogen and a- C. After the preliminary tree hydrogen and nitr 3:1 passed ever 6., and good yields of the process preferably i, culatory process the from the circulating stree n and the gases, ble adjust being recirculated over the contact In the claims the term permuto etic base exchange bodies, siiic" the products obtained by le change bodies with acids of centration so that the honeycoii. structure of the e c stroyed and salt-like boo; s o tion of. the base eachnce bodies v tn c the acid radicals of y with base exchange be which behave like salt claims, he term perinuto other meaning.

This application is part a continuation of my prior applications Serial No. 142,783, filed October 19, 1e26, Serial No. 171,727, filed February 28, rear, which matured into Patents No. 1,728,732 dated September 17, 1929, and No. 1,694,620 dated December 1 1928, respectively.

What is claimed as new 1. A method of synthesis monia from its elements, which c ises passing a gaseous m vs.

L) 'nonia are obtained, (1 as a cirl ilae physical roduce products en '0 used in the ietic wi'ii have no mixture containing hydrogen and nitrogen at an elevated temperature over a contact mass containing a permutogenetic body having catalytically active components, at least one catalytically effective component thereof being chemically combined in or with the perinutogenetic body.

i. A method of synthesizing ammonia from its elements, which comprises passing a gaseous mixture containing hydrogen and nitrogen at an elevated temperature over a contact mass containing a permutogenetic body, at least one catalytically effective component being chemically combined in or with the perinutogenetic body in non exchangeable form.

5. A method of synthesizing ammonia from its elements, which co; rises passing a gaseous mixture containing hydrogen and nitrogen at an elevated temperature over a, contact mass containing a permutogenetic body, having catalytically active components at least one catalytically effective component thereof containing 1ron.

6. A method of synthesizing ammonia from an elevated temperature over a contact masscontaining at least one catalytically permutegenetic body coated onto massive carrier fragments.

ALPHONS O. JAEGER. 

